Non-dimpling fastener

Abstract

Non-dimpling fasteners and methods of installing non-dimpling fasteners are provided herein. Non-dimpling fasteners can include a body including a first end and a second end, a tip at the first end of the body, a head at the second end of the body, a first body portion adjacent to the tip, a second body portion adjacent to the head, and a shoulder adjacent to the first body portion and the second body portion. The first body portion can have a first diameter and can include a first thread. The second body portion can have a second diameter that is larger than the first diameter of the first body portion. The shoulder can have an angle with respect to a longitudinal axis of the fastener.

What is claimed is: 
     
       1. A non-dimpling fastener comprising:
 a body including a first end and a second end, 
 a tip at the first end of the body, 
 a head at the second end of the body, 
 a first body portion adjacent to the tip, the first body portion having a circular cross section with a first diameter, 
 a second body portion adjacent to the head, the second body portion having a circular cross section with a second diameter that is larger than the first diameter of the first body portion, 
 a shoulder adjacent to the first body portion and the second body portion, the shoulder having an angle with respect to a longitudinal axis of the fastener and being configured as a predetermined stopping point along the length of the fastener that causes the fastener to stop during installation when the shoulder encounters a frame element in order to prevent dimpling of an exterior panel; and 
 a first thread that is a continuous thread extending from at least the first body portion, along the shoulder, to an intermediate point on the second body portion. 
 
     
     
       2. The non-dimpling fastener of  claim 1 , wherein the second body portion includes a second thread that is separate from the first thread of the first body portion. 
     
     
       3. The non-dimpling fastener of  claim 2 , wherein the second body portion includes a second thread near the head of the fastener and an unthreaded section between the first thread and the second thread. 
     
     
       4. The non-dimpling fastener of  claim 3 , wherein the unthreaded section has as width that is equal to from about two turns of the first thread to about four turns of the first thread. 
     
     
       5. The non-dimpling fastener of  claim 1 , wherein the shoulder is tapered. 
     
     
       6. The non-dimpling fastener of  claim 1 , wherein the angle of the shoulder is from about 40° to about 90°. 
     
     
       7. The non-dimpling fastener of  claim 6 , wherein the angle of the shoulder is about 40°. 
     
     
       8. The non-dimpling, fastener of  claim 7 , wherein the angle of the shoulder is about 90°. 
     
     
       9. The non-dimpling fastener of  claim 1 , wherein the tip includes a self-drilling point or a self-tapping point. 
     
     
       10. The non-dimpling fastener of  claim 1 , wherein the head includes a washer integrally formed with the head. 
     
     
       11. The non-dimpling fastener of  claim 10 , wherein the washer is an undercut washer. 
     
     
       12. The non-dimpling fastener of  claim 1 , wherein the fastener is constructed from steel, aluminum, or plastic. 
     
     
       13. The non-dimpling fastener of  claim 1 , wherein the fastener has as length from about 1 inch to about 3 inches. 
     
     
       14. A non-dimpling fastener comprising:
 a body including a first end and a second end, 
 a tip at the first end of the body, 
 a head at the second end of the body, 
 a first body portion adjacent to the tip, the first body portion having a circular cross section with a first diameter, 
 a second body portion adjacent to the head, the second body portion having a circular cross section with a second diameter that is larger than the first diameter of the first body portion, 
 a shoulder adjacent to the first body portion and the second body portion, the shoulder having an angle with respect to a longitudinal axis of the fastener and being configured as a predetermined stopping point along the length of the fastener that causes the fastener to step during installation when the shoulder encounters a frame element in order to prevent dimpling of an exterior panel, and 
 a first thread that is a continuous thread that extends from at least the first body portion, along the shoulder, to an intermediate point on the second body portion, 
 wherein the second body portion includes a second thread near the head of the fastener and an unthreaded section on the second body portion between the first thread and the second thread. 
 
     
     
       15. The non-dimpling fastener of  claim 14 , wherein the angle of the shoulder is from about 40° to about 90°. 
     
     
       16. The non-dimpling fastener of  claim 14 , wherein the tip includes a self-drilling point or a self-tapping point. 
     
     
       17. A method of attaching a metal exterior building panel to a metal frame element using a non-dimpling fastener, the method including the steps of:
 providing a metal exterior building panel; 
 providing a metal frame member; 
 providing a fastener, the fastener including:
 a body including a first end and a second end, 
 a tip at the first end of the body, 
 a head at the second end of the body, 
 a first body portion adjacent to the tip, the first body portion having a circular cross section with a first diameter, 
 a second body portion adjacent to the head, the second body portion having circular cross section with a second diameter that is larger than the first diameter of the first body portion, 
 a shoulder adjacent to the first body portion and the second body portion, the shoulder having an angle with respect to a longitudinal axis of the fastener and being configured as a predetermined stopping point along the length of the fastener that causes the fastener to stop during installation when the shoulder encounters a frame element in order to prevent dimpling of an exterior panel; and 
 a first thread that is a continuous thread extending from at least the first body portion, along the shoulder, to an intermediate point on the second body portion; and 
 
 inserting the fastener through the metal exterior building panel and the metal frame element wherein the shoulder having the first thread causes the fastener to stop when the shoulder encounters the frame element, the second body portion of the fastener is positioned through the exterior panel, and the first body portion of the fastener is positioned within the frame. 
 
     
     
       18. The method of  claim 17 , wherein the wherein the angle of the shoulder is from about 40° to about 90°.